Container with product visualization aperture

ABSTRACT

The present invention relates to a method for providing a product viewing window in a container. The container has at least a body ply and a liner ply, wherein the body ply has at least one aperture therethrough. The liner ply is adhered across the aperture, forming a window into the container. A window-finishing machine that comprises at least two platens and, optionally, a machine pocket positioned between them, a heating element extending through at least one of the platens, and a pressurized air device engages a container. The heating element heats the window of the container to the desired temperature, pressurized air is injected into the container such that the window is forced at least partially through the aperture of the container (and optionally into contact with the machine pocket wall), and the container window is then cooled to the desired temperature.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/698,226, filed Sep. 7, 2017 entitled “CONTAINER WITH PRODUCTVISUALIZATION APERTURE”, which is incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to containers with productvisualization apertures, methods for making such containers, and devicesutilized to make such containers.

SUMMARY OF THE INVENTION

According to an aspect, the present invention provides a method forproviding a product viewing window in a container, the methodcomprising: providing at least one container having a body, a first end,and a second end opposite the first end, wherein the container bodycomprises at least a body ply and a liner ply, and wherein the body plyhas an inner surface and an outer surface and defines at least oneaperture therethrough; and wherein the liner ply is adhered to the innersurface of the body ply and has a portion extending across saidaperture, forming a window into the container; providing awindow-finishing machine that comprises: at least one first platen; atleast one second platen; at least one machine pocket positioned betweenthe at least one first and the at least one second platen, wherein theat least one machine pocket has an inside wall; a heating elementextending through the at least one first or the at least one secondplaten; and a pressurized air device that is adapted to releasepressurized air into the container through the at least one first or theat least one second platen; engaging the first end of the container withthe first platen and engaging the second end of the container with thesecond platen, wherein the engagement of the container is airtight;positioning the container window adjacent the inside wall of the machinepocket; positioning the heating element such that it is adapted to heatthe window of the container; heating the window of the container to thedesired temperature; injecting pressurized air into the container suchthat the liner ply window is forced at least partially through theaperture of the container and into contact with the machine pocket wall;and allowing the container window to cool to the desired temperature.

According to another aspect, the present invention also provides awindow-finishing machine adapted to receive a container having a body, afirst end, and a second end opposite the first end, wherein thecontainer body comprises at least a body ply and a liner ply, andwherein the body ply has an inner surface and an outer surface anddefines at least one aperture therethrough; and wherein the liner ply isadhered to the inner surface of the body ply and has a portion extendingacross said aperture, forming a window into the container, wherein themachine comprises: at least one first platen; at least one secondplaten, wherein the at least one first and second platens are adapted toengage the first end of the container with the first platen and thesecond end of the container with the second platen, wherein theengagement of the container is airtight; at least one machine pocketpositioned between the at least one first and the at least one secondplaten, wherein the at least one machine pocket has an inside walladapted to receive the container window; a heating element extendingthrough the at least one first or the at least one second platen,wherein the heating element is positioned to heat the window of thecontainer; and a pressurized air device that is adapted to releasepressurized air into the container through the at least one first or theat least one second platen.

According to yet another aspect, the present invention also provides amethod for providing a product viewing window in a container, the methodcomprising: providing at least one container having a body, a first end,and a second end opposite the first end, wherein the container bodycomprises at least a body ply and a liner ply, and wherein the body plyhas an inner surface and an outer surface and defines at least oneaperture therethrough; and wherein the liner ply is adhered to the innersurface of the body ply and has a portion extending across saidaperture, forming a window into the container; providing awindow-finishing machine that comprises: at least one first platen; atleast one second platen; a heating element extending through the atleast one first or the at least one second platen; and a pressurized airdevice that is adapted to release pressurized air into the containerthrough the at least one first or the at least one second platen;engaging the first end of the container with the first platen andengaging the second end of the container with the second platen, whereinthe engagement of the container is airtight; positioning the heatingelement such that it is adapted to heat the window of the container;heating the window of the container to the desired temperature;injecting pressurized air into the container such that the liner plywindow is forced at least partially through the aperture of thecontainer; and allowing the container window to cool to the desiredtemperature.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate one or more embodiments of theinvention and, together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendeddrawings, in which:

FIG. 1 is a front view of an embodiment of a container of the presentinvention;

FIG. 2 is a front view of an embodiment of a container of the presentinvention;

FIG. 3 is a top schematic view of an apparatus for constructing tubularcontainers with viewing windows according to an embodiment of thepresent invention.

FIG. 4 is a top schematic view of an apparatus for constructing tubularcontainers with viewing windows according to an embodiment of thepresent invention.

FIG. 5 is a cross-sectional view of a container and apparatus forconstructing tubular containers with viewing windows according to anembodiment of the present invention.

FIGS. 6A-B are cross-sectional views of a container and apparatus forconstructing tubular containers with viewing windows according to anembodiment of the present invention.

FIG. 7 is a cross-sectional view of a container according to anembodiment of the present invention.

FIG. 8 is a cross-sectional view of a container according to anembodiment of the present invention.

FIG. 9 is a perspective view of a machine pocket, part of the apparatusfor constructing tubular containers with viewing windows according to anembodiment of the present invention.

FIGS. 10A-D illustrate top cross-sectional views of embodiments of acontainer of the invention.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to presently preferred embodimentsof the invention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation ofthe invention, not limitation of the invention. In fact, it will beapparent to those skilled in the art that modifications and variationscan be made in the present invention without departing from the scope orspirit thereof. For instance, features illustrated or described as partof one embodiment may be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

A variety of food, drink, and non-food products are packaged usingtubular composite containers that are sealed at both ends. In manycases, the tubular composite containers have at least one structuralbody ply and are formed by wrapped a continuous strip of body plymaterial around a mandrel of a desired shape to create a tubularstructure. The body ply material may be spirally wound around themandrel or passed through a series of forming elements so as to bewrapped in a convolute shape around the mandrel. At the downstream endof the mandrel, the tube is typically cut into discrete lengths and isthen fitted with end caps to form the container.

To assist consumers in making purchasing decisions, it is desirable toprovide a tubular composite container for products constructed with oneor more windows or apertures in the container wall to enable theconsumer to view the product stored therein. An aperture or window intothe container not only provides the consumer with the ability to comparethe appearance of competing products, but also provides the consumerwith confidence that the product does not have any defects, such as foodspoilage in the case of food products, prior to making a purchase.

Cutting a product viewing window or aperture into a spirally wound orlinearly drawn paper or composite container, particularly a window thatis cut after the container is formed, has typically had a negativeeffect on the structural integrity of the container. In many of thesecontainers, as the size of the aperture increases, the strength of thecontainer decreases.

Additionally, the film window has typically been adhered flush with theinside wall of the container, impeding the viewability of the productitself as compared to a window that is flush with the outside wall ofthe container.

The present invention provides a multi-ply tubular container having awindow for viewing the product contained therein. In an embodiment, thewindow is formed in a paperboard body ply and is covered by atransparent or translucent polymeric thermoformable liner ply on theinner surface thereof. In this manner, the product can be viewed throughthe window. The liner ply prevents liquids (such as juice, in the caseof food products), and particulates from leaking out of the containerand also prevents liquids and particulates from entering the containerand possibly contaminating or damaging the product stored therein. In anembodiment, the liner ply is also resistant to the passage of gasses, soas to prevent any odors of the product in the container from escapingand to prevent atmospheric air from entering the container and spoilingor damaging the product contained therein. In an embodiment, the linerply provides barrier properties to protect against the migration ofmoisture, water vapor, oxygen, solvents, or other compounds or gasesinto or out of the container.

In an embodiment, the container is constructed in a manner in which thestructural integrity of the container is not compromised due to thewindow or aperture, or is only minimally compromised. In anotherembodiment, the window contributes to or improves the structuralstrength of the container. In a particular embodiment, the window ispositioned flush with the outside of the container, or even extendsbeyond the outside surface of the container, providing improvedviewability of the container contents.

In an embodiment, the container of the present invention may be used tostore (i) food products that are packaged in a liquid, such as peas orcorn; (ii) dry food products, such as powdered drink mixes, infantformula, or potato chips; or (iii) beverages. In another embodiment, thecontainer of the present invention may be used to store various non-foodproducts, such as nails, bolts, paperclips, or safety pins. In fact, thecontainer of the present invention may be useful in storage of anyconsumer product that would benefit from viewability of the containercontents. In an embodiment, the container is capable of beingmanufactured efficiently and inexpensively.

In an embodiment, the liner ply from which the window is formed can be apolymeric material having a low opacity that allows the product in thecontainer to be easily viewed. For example, in an embodiment, the linerply may comprise polyethylene, polypropylene, polyvinylchloride, orpolyethylene terephthalate (“PET”). Any liner ply known in the art maybe used herein. In one embodiment, the liner ply may be substantially orpartially transparent or translucent. The liner ply may include apolymeric moisture barrier layer, such as a polyolefin polymer. In otherembodiments, the moisture barrier layer may include at least one of thegroup of polyester, nylon, ethylene vinyl alcohol copolymer and blendsthereof. In an embodiment, the liner ply has a thickness of less thanabout three mils. In another embodiment, the liner ply has a thicknessof between about 0.5 mils and 20 mils.

In an embodiment, the container may be constructed of at least one bodyply formed of a fibrous paperboard. The body ply may be wrapped into atubular shape having an inner surface and an outer surface. The body plymay define at least one aperture therethrough such that when the bodyply is wrapped or drawn into a tubular shape the aperture forms a windowinto the container. In an embodiment, the body ply defines multipleproduct viewing apertures therethrough. The liner ply may be adhered tothe inner surface of the body ply such that a portion of the liner plyextends across the aperture in the body ply. In an embodiment, the linerply is adhered to the inner surface of the body ply with a wet adhesiveor a polymeric adhesive. The tubular container may optionally include alabel ply adhered to the outer surface of the body ply. The label plymay define at least one aperture therethrough corresponding to theaperture in the body ply or may be transparent where the aperture in thebody ply is located. The body ply and liner ply can be spirally wound,convolutely wound, helically wound, linearly drawn, or longitudinally,perpendicularly wound, and/or any combination thereof or using any othermethod known.

The present invention provides a method of manufacturing multi-plytubular containers having a window for viewing the product containedtherein. In an embodiment, the method includes advancing a continuouspolymeric liner ply towards and wrapping the liner ply around a shapingmandrel to create a tubular shape. In this embodiment, a continuous bodyply formed of paperboard is also advanced towards the mandrel. Aperturesare cut in the body ply at predetermined intervals along its lengthbefore it reaches the mandrel. An adhesive may be applied to the insidesurface of the body ply. The body ply then reaches the mandrel and iswrapped around the previously wrapped liner ply on the mandrel so thatthe liner ply becomes adhered to the body ply to create a tubular shapehaving one or more viewing windows. Once constructed, the tubular shapemay be cut into discrete lengths. The parent tube may be cut intodiscrete lengths adjacent the end of the mandrel or in an entirelyseparate cutting station, optionally on a different mandrel. Optionally,at least one end of each discrete tube length can then be rolledoutwardly to form a bead, or a flange for a metal end. In an embodiment,the liner ply is elastically deformable to prevent the bead fromunrolling.

The parent tube or the cut container tubes may, in an embodiment, thenbe advanced to a window-finishing machine. The window-finishing machinemay orient the tubes/containers vertically or horizontally. Thewindow-finishing machine may, in an embodiment, comprise a rotary turretmachine that supports one or more machine pockets spaced about thecircumference of its main turret. Each pocket may be spaced andconfigured to hold, position, or nest with a composite container asdescribed herein. In an embodiment, the machine pockets may be shapedhalf-cylindrically (or may form any portion of a cylindrical shape whichmatches the shape of the cut tubes). In an embodiment, the machinepockets are designed such that the containers described herein may nestwith the machine pockets. More specifically, the window of the containermay be nested against the wall of the machine pocket in an embodiment ofthe invention. The window-finishing machine may further comprise one ormore upper and lower platens (also referred to herein as first andsecond platens) positioned above and below each pocket, configured tomove toward and enclose each end of the container between them in anairtight manner, as the container simultaneously rests against or nestswith the machine pocket wall. Each of the upper and lower platens mayremovably engage with an opposite end of the container.

The window-finishing machine may additionally include a cam which islocated above, to the side, and/or beneath the turntable and is in thegeneral form of a ring concentric with the turntable and extending aboveor beneath the circular path along which the containers are advanced, asthe turntable is rotated about its axis. The cam may engage liftersattached to the upper and/or lower platens or may directly engage theupper and/or lower platens. As the turntable is rotated about its axis,the lifter and/or upper or lower platen for a given machine pocket mayrise according to the cam profile, thereby lifting the container inorder to engage with the other platen and finish the window inaccordance with the invention. Thereafter, the lifter and/or upper orlower platen may lower according to the cam profile, thereby loweringthe container in order to allow the container to be advanced to the nextposition.

In another embodiment, the window-finishing machine does not includemachine pockets. In this embodiment, the window-finishing machine mayorient the tubes/containers vertically or horizontally. Thewindow-finishing machine may, in an embodiment, comprise a rotary turretmachine that supports one or more upper and lower platens (also referredto herein as first and second platens), positioned and configured tomove toward and engage each end of the container between them in anairtight manner. Each of the upper and lower platens may removablyengage with an opposite end of the container.

In the position wherein the container is engaged with the upper andlower platens, a heating element may be present within the platen, maybe inserted through the upper and/or lower platen, or may be positionedon the outside of the upper and/or lower platen, adjacent the containerbody. The heating element may be positioned near and/or directed towardthe interior or exterior of the product visualization window. In anembodiment, this heating element allows the softening of the portion ofthe liner ply that is located within the window. Once the liner plypositioned within the aperture reaches the desired temperature, thecontainer body may then be pressurized with air, forcing the liner plypositioned within the aperture to form into and/or through the aperture.A pressurized air device may be present within the platen or may beinserted through the upper and/or lower platen in an airtight manner.The pressurized air device may be positioned near and/or directed towardthe interior of the product visualization window. In an embodiment, thesoftened liner ply is forced at least partially through the aperture,due to the increased air pressure. In a particular embodiment, thesoftened liner ply then comes into contact with the machine pocket wall.In another embodiment, the liner ply does not contact a machine pocketwall. In either case, the liner ply is then cooled. The container isthen advanced out of the window-finishing machine.

With reference now to the drawings, a tubular container 10 according tothe present invention is illustrated in FIG. 1. Although illustrated asa cylinder having a circular cross section, the tube may have any crosssectional shape that can be formed by wrapping or drawing the tubearound an appropriately shaped mandrel. One example is a generallyrectangular shaped tube having rounded corners. The embodimentillustrated in FIG. 1 may include various end closures, depending uponthe type of product which is to be packaged.

As illustrated in more detail in FIG. 2, the tubular container 10includes a body ply 12, which is preferably formed of paperboard, aliner ply 14, which is preferably formed of a thermoformable polymerfilm and is adhered to the inner surface of the body ply, and anoptional label ply 15, which may have various indicia printed thereonregarding the product within the container. The label ply 15 may beadhered to the outer surface of the body ply. The upper end of thetubular container may be rolled over so as to form either a bead (notshown) or flange for metal end or closure. An end cap 11 may be snappedover the bead and may be reused. A metal, laminated, or any other typeof closure known in the art (not shown) can be secured to the oppositeend of the container or to both ends.

In an embodiment, the liner ply 14 is transparent, although translucentand slightly opaque liner materials which allow some visibility of theproduct packaged therein could be used. An optional additional barrierlayer may be utilized, which may be resistant to the passage of liquidsand gasses such as oxygen. If a barrier is required for both liquids andgasses, an exemplary barrier material that may be used is polyester.Alternative barrier materials may include nylon, EVOH (ethylene vinylalcohol polymer and copolymer), polyvinylidene chloride, polyethylene,polypropylene, and silicon dioxide coated polymers and the like, as willbe apparent to the skilled artisan. It will be understood that variousbarrier materials or properties could be employed depending upon theitem being packaged. In various embodiments, the barrier materials couldbe incorporated into the liner ply 14 or provided as a separatematerial.

In an embodiment, the paperboard body ply 12 is made of a relativelythick and stiff paperboard. Any paperboard known in the art may be usedin this invention. The body ply has at least one aperture 16 cuttherethrough, as illustrated in FIGS. 1 and 2. In an embodiment, thelabel ply may have an aperture 17 cut therethrough corresponding to theaperture 16 cut in the body ply. In another embodiment, the label plymay be transparent in the areas corresponding to the aperture 16 cut inthe body ply.

An exemplary apparatus for constructing tubular containers with viewingwindows according to an embodiment of the present invention isillustrated in FIG. 3. In an embodiment, a continuous strip of liner plymaterial 14 is fed from a reel (not shown) to the apparatus. The linerply may then be helically wrapped about the mandrel 26.

After the liner ply 14 is wrapped about the mandrel 26, a body ply 12may be wrapped around the liner ply 14 and adhesively secured thereto. Acontinuous strip of paperboard body ply material 12 is fed from a reel(not shown) to the apparatus. The body ply 12 may be advanced through acutting die 23, which selectively cuts openings 16 through the body plyalong the length of the body ply. In an embodiment, the cutting die 23is a servo-controlled rotary die. In another embodiment, the cutting die23 is a laser cutter. In another embodiment, the cutting die 23 is awater-jet cutter, a rotary die, a kiss-cutter die, or any other cuttingdevice known in the art. In any event, openings 16 are cut into the bodyply 12 prior to winding on the mandrel 26. Openings 16 may be any shapeknown in the art—square, circular, rectangular, triangular,diamond-shaped, or any other shape.

In an embodiment, the body ply 12 is then advanced through an adhesiveapplicator 35, which applies an adhesive 21 to the inner surface 81 ofthe body ply 12. The adhesive 21 may be an aqueous adhesive or asolvent-based adhesive. In an embodiment, the adhesive 21 will notinterfere with the transparency of the liner ply 14. In an embodiment,the adhesive is applied to the inner surface of the body ply 12, ratherthan to the liner ply 14, which avoids application of adhesive to thewindow portion itself.

In an optional embodiment, the body ply 12 and adhesive 21 appliedthereto may then be passed underneath a heater 37 that evaporates atleast part of the water content of the aqueous adhesive 21 to render theadhesive substantially tacky. A particular type of heat source that maybe used is an infrared heater although various other heat sources, e.g.,forced air heating or the like can be used.

In an embodiment, the body ply 12 is then wrapped around the shapingmandrel 26 over the previously wrapped liner ply 14. In an embodiment,the body ply 12 is first wrapped under the mandrel then back over thetop in a helical fashion. The inner surface of the body ply 12 comesinto contact with the outer surface of the liner ply 14, which isexposed on the mandrel, and becomes adhered thereto. In an embodiment,multiple contiguous structural body plies can be used. The tube is thenadvanced down the mandrel 26 by a tube conveyor, such as a conventionalwinding belt 38, which extends around a pair of opposed pulleys 41.

In an embodiment, a label ply 15 may then be attached to the outersurface 82 of the body ply 12. As illustrated in FIG. 3, a continuousstrip of pre-printed label ply 15 is fed from a reel (not shown) to theapparatus. The label ply 15 may be advanced through a cutting die 40,which selectively cuts openings 17 through the label ply 15 along thelength of the label ply 15. Preferably, the label ply 15 is printed withan optically or magnetically readable eye mark or other locating device.As the label ply 15 approaches the die cutter 40, the locating device isregistered by an encoder, which then provides a signal to the labelrotary die 40 instructing the rotary die to make a cut. This allows thecut in the label ply 15 to be formed in a desired spatial relationshipto the decorative print pattern such that, for example, the window inthe container can be “framed” by the printed pattern on the label.

In an embodiment, the label ply 15 is then passed over an adhesiveapplicator 42. The label ply 15 is then wrapped around the body ply 12.In an embodiment, the label ply 15 could be applied to the body ply 12before or after the winding belt 38.

In a separate embodiment, the container 10 could be formed as set forthabove, but without cutting the windows 16, 17 into the body ply 12 andlabel ply 15 prior to wrapping on the mandrel 26. In this embodiment,the liner ply 14 is wrapped about the mandrel 26, the body ply 12 iswrapped about the liner ply 14 and adhered thereto, the label ply 15 iswrapped about the body ply 12 and adhered thereto, and then thecomposite container is passed through a cutting station. This could be adie cutting station, a laser cutting station, or any other cuttingstation known in the art. In this embodiment, one or more windows is cutthrough the optionally label ply 15 and the body ply 12, but does notcut through the liner ply 14. Accordingly, a window 16 is present in thecontainer 10.

In either embodiment, at a cutting station 43, the continuous tube maybe cut into discrete lengths. As shown in FIG. 4, in an embodiment, thecontainers 10 are then oriented and advanced to a window-finishingmachine 50. The containers 10 may be oriented vertically orhorizontally, depending on the format of the window-finishing machine50.

In another separate embodiment, the container 10 could be formed as setforth above, but without applying liner ply 14 to the interior of bodyply 12. In this embodiment, the container may comprise body ply 12containing window 16 and, optionally, label ply 15. In this embodiment,the liner ply 14 could be applied to the interior of the continuous tubeor the discrete lengths of container tube in the form of a “patch.” Thatis, the liner ply 14 patch could be configured and sized to besubstantially similar in size, or larger than, the window 16. The patchcould be applied to the interior of the body ply 12 by inserting itwithin the container shape and pressing it against the interior of thebody ply 12 about the window 16. The patch could be sealed to the bodyply 12 using a heat seal, a pressure sensitive seal, or any othersealing method known in the art.

Similarly, in yet another separate embodiment, the container 10 could beformed as set forth above but without cutting the windows 16, 17 intothe body ply 12 and label ply 15 prior to wrapping on the mandrel 26. Inthis embodiment, the liner ply 14 is wrapped about the mandrel 26, thebody ply 12 is wrapped about the liner ply 14 and adhered thereto, thelabel ply 15 is wrapped about the body ply 12 and adhered thereto, andthen the composite container is passed through a cutting station. Thiscould be a die cutting station, a laser cutting station, or any othercutting station known in the art. In this embodiment, one or morewindows is cut through the optional label ply 15, the body ply 12, andthe liner ply 14. A window 16 is then present in the container 10. Inthis embodiment, a patch could be configured and sized to besubstantially similar in size, or larger than, the window 16. The patchcould be applied to the interior of the container by inserting it withinthe container shape and pressing it against the interior of the linerply 14 about the window 16. The patch could be sealed to the liner ply14 using a heat seal, a pressure sensitive seal, or any other sealingmethod known in the art. The patch may be made from the same material asthe liner ply 14.

Although a spiral wound container is described and shown in the Figures,it should be understood that any winding method known in the art couldbe utilized to form the container.

In an embodiment, the window-finishing machine 50 may comprise amulti-head/position continuous motion rotary machine that has upper andlower platens for airtight sealing of both ends of the container body.As shown in FIG. 4, the window-finishing machine 50 may comprise arotating turntable 53 and a main rotary turret 59 that, in anembodiment, supports one or more machine pockets 52 spaced about itscircumference, each spaced and configured to hold, position, or nestwith a container 10. As each container 10 feeds into the main rotaryturret 59, preferably with the container in an upright orientation, therotary unit clamps both ends of the container 10 in an airtight manner.In an embodiment, either the top or the bottom clamping plate (orplatens, described below) has a heating element 68 extending through theclamping plate. In an embodiment, the position of the heating element 68is able to be adjusted vertically or horizontally by a cam function inthe rotary unit turret 59.

In an embodiment, the window-finishing machine 50 may comprise an infeedconveyor 54 which advances the containers 10 into the window-finishingmachine 50. In an embodiment, the window-finishing machine 50 may alsocomprise a feed screw 55 or any other suitable type of mechanism forconveying the containers 10 to the window-finishing machine 50. Thewindow-finishing machine 50 may also comprise one or more infeed starwheels 58, designed to advance a container 10 from the infeed conveyor54 to the main turret 59. Similarly, the window-finishing machine 50 maycomprise one or more outfeed star wheels 57, designed to advance acontainer 10 from the main turret 59 to the outfeed conveyor 56. Itshould be understood that any configuration of the various elements ofthe window-finishing machine 50 may be utilized in connection with thepresent invention.

In an embodiment, the machine pockets 52 may be substantiallyhalf-cylindrically shaped (shown in FIG. 9) such that the window 16 ofthe containers 10 may nest with the inside wall of the machine pockets52. In other embodiments, the machine pockets 52 may be cylindrical orsubstantially cylindrical and may cover up to the full three hundredsixty degrees 360° of circumference of the container. This may allow themachine pockets 52, in an embodiment, to simultaneously addresswindows/apertures on opposite walls of the container as is furtherdescribed herein. For example, a container 10 may have a window on thefront and the back sidewall and the machine pocket 52 may substantiallysurround the container 10 in order to enclose the container 10. In stillanother embodiment, the machine pockets 52 may be less thanhalf-cylindrically sized. In an embodiment, the shape of the machinepockets 52 may be any shape known in the art, but matches the shape ofthe containers 10.

The window-finishing machine 50 may further comprise one or more upper62 and lower 61 platens (shown in FIGS. 5-6), configured to move toward,clamp, and/or enclose the container 10 between them in an airtightmanner, as the container simultaneously rests against or nests with themachine pocket 52 wall. Each of the upper 62 and lower 61 platens mayremovably engage with an opposite end of the container 10.

In the position wherein the container is engaged with the upper 62 andlower 61 platens, a heating element 68 (shown in FIG. 5) may bepositioned within or inserted through the upper 62 and/or lower 61platen. The heating element 68 may be positioned near or adjacent to ormay be directed toward the interior of the product visualization window16. The orientation of the heating element 68 should direct the heattoward the window 16. In an embodiment, the heating element 68 heats andsoftens the portion of the liner ply 14 located within the window 16. Itmay be desirable to heat the liner ply 14 to a temperature that is at ornear the glass transition point or melting point of the particularpolymeric material or film that is utilized as the liner ply 14. One ofordinary skill in the art will understand that this temperature willvary greatly depending on the material utilized for the liner ply 14.

In an embodiment, the heating element 68 comprises a resistance coildesign, although other systems known in the art, such as Infrared,quartz, or halogen, could be utilized. In an embodiment, forced hot airis utilized in the invention to assist in moving the heat toward thecontainer window 16. In an embodiment, the heating element 68 uses ashielding system to direct the heat toward the window 16 while limitingthe heat effect on the remainder of the inner wall of the container. Inan embodiment, the heating element is presented within the machinepocket, such that the machine pocket directs heat toward the window tosoften it. In another embodiment, the heating element 68 is presented onthe exterior of the container body and the window 16 is heated beforethe pocket is applied to the container body.

After the liner ply 14 positioned within the aperture 16 reaches thedesired temperature, the container body 10 may then be pressurized withair. In an embodiment, a pressurized air device 69 (shown in FIG. 5) maybe positioned within or inserted through the upper 62 and/or lower 61platen in an airtight manner. The pressurized air device 69 may bepositioned near or directed toward the interior of the productvisualization window 16. In another embodiment, the pressurized air isintroduced into the container body directly through one of the upper 62and/or lower 61 platens. In either embodiment, the pressurized air isreleased within the sealed container, forcing the softened liner ply 14that is positioned within the aperture 16 to be expanded into and/orthrough the aperture 16. The softened liner ply 14 is forced through theaperture 16 until it comes into contact with the inside wall of themachine pocket 67. The liner ply 14 is then cooled against the machinepocket wall 67.

In an embodiment, the machine pocket wall or the relevant insert(discussed below), if any, may be cooled by blown air or liquid (i.e. awater jacket) in order to more quickly cool the liner ply 14. In anembodiment, the formed polymeric window 80 (shown in FIGS. 7-8). will becooled to a temperature at which the window 80 can survive the handlingand conveying of the downstream production equipment. In an embodiment,the window 80 is cooled to a temperature that is at or below the glasstransition or melting point of the polymeric material that is used. Thecooled temperature should be sufficient to avoid any sag, deformation,or distortion in the window 80 once it is advanced out of thewindow-finishing machine 50.

In an embodiment, interior machine pocket wall 67 (shown in FIG. 9) maybe smooth, textured (shown in FIG. 9 as a corrugated texture 70),contoured, or may have an imprinted logo or text. As the softened linerply 14 contacts the machine pocket wall 67 and cools, it will mold to,or mirror, the surface texture of the machine pocket wall 67. Theresulting container 10 will have a product visualization window 80 thatis smooth, textured, contoured, embossed, or has an imprinted logo ortext, each based upon the contouring of the inner surface of the machinepocket wall 67. For example, if the machine pocket wall has a corrugatedtextured surface 70, this corrugated texture may be permanently formedinto the film in the product visualization window 80 as it cools. In anembodiment, the contour of the machine pocket wall 67 may be adjusted byplacement of various inserts into a slot in the machine pocket wall 67.For example, a corrugated insert may be placed in the slot for aparticular container and a smooth insert may be placed in the slot for adifferent container.

In an embodiment, the texture of the machine pocket wall 67 is designedto impart a structural benefit to the product visualization window 80.In this embodiment, the product visualization window 80 contributes toand/or improves the overall structural integrity of the container. Forexample, the machine pocket wall 67 could impart a corrugated, columned,v-shaped, arched, circular, or triangular structure to the productvisualization window.

In an embodiment, the inventive method, device, and container provide aproduct visualization window 80 that is flush with the inside wall ofthe container 10. Pressurized air may or may not be utilized in thisembodiment. In another embodiment, the product visualization window 80may be flush with the outside wall of the container 10, potentiallyproviding improved viewability of the container contents (shown in FIG.7).

In another embodiment, the inventive method and container provide aproduct visualization window 80 that extends a particular distance pastthe outside wall of the container, controlled by the distance betweenthe container 10 and the machine pocket wall 67. In this embodiment, thewindow finishing machine 50 may position the container 10 a suitabledistance away from the machine pocket wall 67. When the liner ply 14 isheated and air pressurized, it is forced through the aperture 16 untilit contacts the machine pocket wall 67. If the machine pocket wall 67 ispositioned a controlled distance away from the container 10, the linerply 14 will be forced beyond the surface of the container before itcontacts the machine pocket wall 67. The liner ply 14 will then becooled, creating a product visualization window 80 that extends aparticular distance past the outside wall of the container 10 (shown inFIG. 8).

In an alternative embodiment, a product visualization window 80 thatextends a particular distance past the outside wall of the container maybe created by providing a machine pocket wall 67 that is recessed. Thus,the container 10 nests against the recessed machine pocket wall 67. Whenthe liner ply 14 is heated and air pressurized, it is forced through theaperture 16 until it contacts the recessed machine pocket wall 67. Theliner ply 14 will then be cooled, creating a product visualizationwindow 80 that extends a particular distance past the outside wall ofthe container 10.

Further, if desired, the machine pocket wall 67 may be designed toproduce a product visualization window 80 which is recessed within thecontainer wall. In this embodiment, the machine pocket wall 67 may bedesigned such that it extends into the aperture 16. Before or after theliner ply 14 is heated, the machine pocket wall 67 may be contacted withthe container, extending at least partially into the aperture 16. Inthis embodiment, pressurized air may or may not be utilized. The linerply 14 will then be cooled, creating a product visualization window 80that is recessed a particular distance inside the wall of the container10. In an embodiment, multiple polymer liner structural elements may bepresent, which may improve the strength characteristics of the windowand container. These multiple polymer liner structural elements mayinclude corrugations, columns, arches, or any other feature which willsupport the body wall where the aperture was formed.

FIGS. 10A-10D illustrate a top cross-section view of the container ofthe invention. In these Figures, the product visualization window isillustrated having a corrugated texture. The corrugations 75 are shownextending various distances in various embodiments. For example, in FIG.10A, the corrugations 75 are shown to extend inward of the body ply 12and outward of the body ply 12. In FIG. 10B, the corrugations 75 areshown to be entirely contained within the width of the body ply 12, suchthat the corrugations are the same width as the interior and exteriorwall of the body ply 12. In FIG. 10C, the corrugations 75 are shown tobegin at the interior wall of the body ply 12, but extend beyond theexterior wall of the body ply 12. In FIG. 10D, the corrugations 75 areshown to extend inward of the interior wall of the body ply 12, but endat the exterior wall of the body ply 12. In an embodiment, thecorrugations 75 extend at least the distance of the interior andexterior walls of the body ply 12, as shown in FIG. 10B.

In any embodiment, after the product visualization window 80 is cooled,the container 10 is then advanced out of the window-finishing machine50. In an embodiment, a finish closure may then be applied to one orboth ends of the container body with or without filling the containerwith a consumer product, each of which may be accomplished usingstandard methods in the art.

In a particular embodiment, the window 80 size can be increased withoutreducing the structural integrity of the container, using the inventivemethod. In still another embodiment, the inventive method and containercan be utilized without sacrificing manufacturing speed andproductivity.

As previously mentioned, the method of constructing containers 10 withwindows for viewing the stored product from outside the containeraccording to the present invention is not limited to one or two bodyplies, but may also be applicable to containers comprising three or morebody plies.

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims. In addition, itshould be understood that aspects of the various embodiments may beinterchanged in whole or in part. Furthermore, those of ordinary skillin the art will appreciate that the foregoing description is by way ofexample only, and is not intended to limit the invention so furtherdescribed in such appended claims. Therefore, the spirit and scope ofthe appended claims should not be limited to the description of theversions contained therein.

What is claimed is:
 1. A window-finishing machine adapted to receive acontainer having a body, a first end, and a second end opposite thefirst end, wherein the body comprises at least a body ply and a filmliner ply, wherein the body ply has an inner surface and an outersurface and defines at least one aperture therethrough, wherein theliner ply is adhered to the inner surface of the body ply and has aportion extending across said at least one aperture, forming a window ofthe container, and wherein the machine comprises: a. at least one firstplaten; b. at least one second platen, wherein the at least one firstplaten is adapted to engage the first end of the container and the atleast one second platen is adapted to engage the second end of thecontainer, wherein the engagement with the container is airtight; c. atleast one machine pocket positioned between the at least one firstplaten and the at least one second platen, wherein the at least onemachine pocket has an inside wall adapted to receive the window; d. aheating element extending through a through hole in the at least onefirst platen or the at least one second platen, wherein the heatingelement is positioned to heat the window of the container; and e. apressurized air device that is adapted to release pressurized air intothe container through the at least one first platen or the at least onesecond platen.
 2. The machine of claim 1, wherein the machine is amulti-position continuous motion rotary machine.
 3. The machine of claim1, further comprising a turret that supports the at least one machinepocket.
 4. The machine of claim 1, wherein the at least one machinepocket is half-cylindrically shaped.
 5. The machine of claim 1, whereinthe heating element is removably inserted through the at least one firstplaten or the at least one second platen.
 6. The machine of claim 1,wherein the inside wall of the at least one machine pocket is contoured.7. The machine of claim 6, wherein the contour of the at least onemachine pocket is selected from the group consisting of smooth,textured, imprinted, columned, v-shaped, triangular, and corrugated. 8.The machine of claim 1, wherein the heating element is configured to beadjustable vertically or horizontally within the container such thatheat is directed toward the window.
 9. The machine of claim 1,additionally comprising a means for cooling the inside wall of the atleast one machine pocket.
 10. The machine of claim 9, wherein the meansfor cooling comprises forced cold air or liquid.
 11. The machine ofclaim 1, wherein the container is cylindrical.
 12. The machine of claim11, wherein the machine pockets are configured at leastpartially-cylindrically.
 13. The machine of claim 1, wherein thecontainer is spirally-wound.
 14. The machine of claim 1, wherein thecontainer is linearly formed around a mandrel.
 15. The machine of claim1, wherein the container is oriented vertically.
 16. A window-finishingmachine adapted to receive a container having a body, a first end, and asecond end opposite the first end, wherein the body comprises at least abody ply and a film liner ply, wherein the body ply has an inner surfaceand an outer surface and defines at least one aperture therethrough,wherein the liner ply is adhered to the inner surface of the body plyand has a portion extending across said at least one aperture, forming awindow of the container, and wherein the machine comprises: a. at leastone first platen; b. at least one second platen, wherein the at leastone first platen is adapted to engage the first end of the container andthe at least one second platen is adapted to engage the second end ofthe container; c. at least one machine pocket positioned between the atleast one first platen and the at least one second platen, wherein theat least one machine pocket has an inside wall adapted to receive thewindow; d. a heating element extending through a through hole in the atleast one first platen or the at least one second platen, wherein theheating element is positioned to heat the window of the container; ande. a pressurized air device that is adapted to release pressurized airinto the container through the at least one first platen or the at leastone second platen.
 17. The machine of claim 16, wherein the heatingelement is removably inserted through the at least one first platen orthe at least one second platen.
 18. The machine of claim 16, wherein theinside wall of the at least one machine pocket is contoured.
 19. Themachine of claim 18, wherein the contour of the at least one machinepocket is selected from the group consisting of smooth, textured,imprinted, columned, v-shaped, triangular, and corrugated.
 20. Themachine of claim 16, additionally comprising forced cold air or liquidfor cooling the inside wall of the at least one machine pocket.